Section 7 Maintenance Standard

SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test -------------------------------------------------------------------------- 7-1

Group 2 Major Components -------------------------------------------------------------------------------------------- 7-22
Group 3 Track and Work Equipment ------------------------------------------------------------------------------- 7-30
SECTION 7 MAINTENANCE STANDARD
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in Working
parts and reassembled at a customer's condition
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
record
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level. Operating
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to
the "Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done. 21077MS01
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and safely.
The machine
(1) Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
Select a hard, flat surface.
Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with each
other using these signals, and to follow
(290-7TIER) 7-3
them without fail.
Operate the machine carefully and always
give first priority to safety.
While testing, always take care to avoid
accidents due to landslides or contact with
high voltage power lines. Always confirm
that there is sufficient space for full swings.
Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
Accurately calibrate test instruments in
advance to obtain correct data.
Carry out tests under the exact test
conditions prescribed for each test item.
Repeat the same test and confirm that the
test data obtained can be procured
r e p e a t e d l y. U s e m e a n va l u e s o f
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
The engine speed at each power mode CLUSTER TYPE 1
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
Warm up the machine, until the engine
coolant temperature reaches 50C or
Engine RPM display
more, and the hydraulic oil is 505C. Power mode switch
Set the accel dial at 10 (Max) position. Pilot lamp(P, S, E)
Measure the engine RPM.
(3) Measurement
Start the engine. The engine will run at CLUSTER TYPE 2
start idle speed. Measure engine speed
with a engine rpm display.
Engine RPM display
Measure and record the engine speed at
each mode.
Select the P-mode (cluster type 1).
Select the M-mode (cluster type 2). Pilot lamp(H, S)
Lightly operate the bucket control lever a Power mode switch
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
Measure and record the auto deceleration
speed. 2209S7MS03
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 850100
P (M) mode 210050
S (H) mode 200050
R220LC-9S
E (S) mode 190050
Auto decel 1150100
One touch decel 1000100
Condition : Set the accel dial at 10 (Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20 m test track.
(2) Preparation
Adjust the tension of both tracks to be
equal.
Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at
21097MS04
505C.
(3) Measurement
Measure both the low and high speeds
of the machine.
Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
Power mode switch :
3~5m 20m 3~5m
P mode (cluster type 1)
M mode (cluster type 2)
Star t traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Measure the time required to travel 20 m.
After measuring the forward travel 21077MS05
speed, turn the upperstructure 180

and measure the reverse travel speed.
Repeat steps and three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20 m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 18.92.0 23.6
R220LC-9S
2 Speed 13.11.0 16.4
7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
Adjust the tension of both side tracks to
be equal.
On the track to be measured, mark one
90~110
shoe with chalk.
Swing the upperstructure 90and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to Mark
110as shown. Place blocks under
machine frame.
21077MS06
505C.
(3) Measurement
Select the following switch positions.
Travel mode switch : 1 or 2 speed
Power mode switch :
Auto idle switch : OFF
Operate the travel control lever of the
raised track in full forward and reverse.
Rotate 1 turn, then measure time taken
for next 3 revolutions.
Raise the other side of machine and
repeat the procedure.
Repeat steps and three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 28.82.0 35.4
R220LC-9S
2 Speed 19.22.0 23.4
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
Adjust the tension of both tracks to be
equal.
Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
21097MS04
505C.
(3) Measurement
Measure the amount of mistracking at
high and low travel speeds.
Before beginning each test, select the
following switch positions.
Power mode switch :
P mode (cluster type 1) 3~5 m extra length
M mode (cluster type 2) a
M
20
Star t traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5 m extra length
Measure the distance between a straight
20 m line and the track made by the
machine. (Dimension a)
After measuring the tracking in forward (210-7) 7-7(2)
travel, turn the upperstructure 180and

measure that in reverse travel.
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
R220LC-9S 200 below 240
7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
505C. 21077MS07
(3) Measurement
Power mode switch :
Operate swing control lever fully.
Swing 1 turn and measure time taken to
swing next 3 revolutions.
Repeat steps and three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power mode switch Standard Maximum allowable
R220LC-9S 15.81.5 19.0
7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360 full speed swing.
(2) Preparation
Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
21097MS07
foot pin. The bucket must be empty.
Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
Swing the upperstructure 360.
505C.
(3) Measurement
Conduct this test in the M mode.
Power mode switch :
Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360 Drift angle
Measure the distance between the two
360 swing
marks. Swing start & stop
Align the marks again, swing 360, then
test the opposite direction.
21077MS08
Repeat steps and three times each
and calculate the average values.
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Power mode switch Standard Maximum allowable Remarks
R220LC-9S 90 below 128.7
7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
Check swing bearing mounting cap
screws for loosening.
Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
Install a dial gauge on the track frame as
shown, using a magnetic base.
Position the upperstructure so that the
(210-7) 7-10(1)
boom aligns with the tracks facing
towards the front idlers.
Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
Bucket should be empty.
(3) Measurement Measurement : (h1)
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
Lower the bucket to the ground and use
it to raise the front idler 50cm.
Measurement : (h2)
Record the dial gauge reading (h2).
Calculate bearing play (H) from this data
(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 21077MS09
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks
R220LC-9S 0.5 ~ 1.5 3.0
7-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation Boom cylinder
To measure the cycle time of the boom Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
Arm cylinder
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5 m
above the ground. Roll out Roll in
To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned 0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground. Bucket cylinder
505C.
(3) Measurement
Power mode switch : Roll out Roll in
P mode (cluster type 1) 0.5m
To measure cylinder cycle times. 21077MS10
- Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
as possible.
7-11
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the bucket
at one stroke end, then move the control
as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Maximum
Model Function Standard Remarks
allowable
Boom raise 3.50.4 4.1
Boom lower 2.50.4 3.2
Regen ON 3.20.4 3.8
Arm in Cluster type 1
Regen OFF 3.70.4 4.5
R220LC-9S
Arm in 3.70.4 4.5 Cluster type 2
Arm out 3.00.3 3.8
Bucket in 2.50.4 3.3
Bucket out 2.30.3 2.9
7-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
W=M31.5
Where :
M3 = Bucket heaped capacity (m3)
1.5= Soil specific gravity
Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
21077MS11
extended position.
foot pin.
505C.
(3) Measurement
Stop the engine.
Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Repeat step three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20
R220LC-9S Arm cylinder 10 below 20
Bucket cylinder 40 below 60
7-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
505C.
(3) Measurement
Start the engine.
Power mode switch
P mode : cluster type 1
M mode : cluster type 2
Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.7 or below 2.0
Arm lever 1.7 or below 2.0
R220LC-9S Bucket lever 1.4 or below 2.0
Swing lever 1.4 or below 2.0
Travel lever 2.1 or below 3.15
7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
505C.
(3) Measurement
Stop the engine.
Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 11210 134
Arm lever 11210 134
R220LC-9S Bucket lever 9010 112
Swing lever 9010 112
Travel lever 13910 178
7-15
13) PILOT PRIMARY PRESSURE (CLUSTER TYPE 1)
Main pump
a3
(1) Preparation
505C. Pressure sensor
(2) Measurement
Power mode switch : P mode
Monitoring
Auto decel switch : OFF (analog)
Measure the primary pilot pressure by
the monitoring menu of the cluster.
Cluster
(3) Evaluation 21097MS12
The average measured pressure should meet the following specifications:

Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R220LC-9S P mode 40 +20 -
PILOT PRIMARY PRESSURE (CLUSTER TYPE 2)
(1) Preparation
Stop the engine.
Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
a3
Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
Star t the engine and check for oil
leakage from the port.
505C.
2507A7MS02A
(2) Measurement
Mode selector : M mode
Auto decel switch : OFF
Measure the primary pilot pressure in the
M mode.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Alowable limits Remarks
R220LC-9S M mode 40 +20 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
Stop the engine.
breather.
To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
Star t the engine and check for on
leakage from the adapter.
505C.
(2) Measurement
Travel mode switch : 1 speed 21077MS13
2 speed
Mode selector :
Measure the travel speed selecting
pressure in the Hi or Lo mode.
Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
(3) Evaluation
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
R220LC-9S
2 Speed 405 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
Stop the engine.
breather. SH
The pressure release L wrench to bleed
air.
assembly to swing motor SH port, as
shown.
leakage from the adapter.
505C.
(2) Measurement 21077MS14

Power mode switch :
Operate the swing function or arm roll in
function and measure the swing brake
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 40 Over 9

R220LC-9S
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 1) Main pump
(1) Preparation
Keep the hydraulic oil temperature at Pressure sensor a1
505C. a2
(2) Measurement
Monitoring
Power mode switch : P mode (analog)
Measure the main pump deliver y
pressure in the P mode (high idle).
Cluster
21097MS15
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R220LC-9S High idle 405 -
MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 2)
(1) Preparation
Stop the engine.
breather.
Push the pressure release button to
bleed air.
To measure the main pump pressure.
assembly main pump gauge port as
shown.
290LC7MS07
505C.
(2) Measurement
Auto decel switch : OFF
Measure the primary pilot pressure in the
M mode.
(3) Evaluation
Unit : kgf / cm2
Model Engine speed Standard Alowable limits Remarks
R220LC-9S High idle 405 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 1)
(1) Preparation
505C.
(2) Measurement Main pump
Power mode switch : P mode
Pressure sensor
Slowly operate each control lever of a1
a2
boom, arm and bucket functions at full
stroke over relief and measure the
pressure. Monitoring
In the swing function, place bucket (analog)
against an immovable object and

measure the relief pressure.
In the travel function, lock undercarriage Cluster
with an immovable object and measure
21097MS15
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Port relief setting at 20 lpm
Boom, Arm, Bucket 350 (380)10 40010

R220LC-9S Travel 35010 -
Swing 26510 -
( ) : Power boost
7-20
SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 2)
(1) Preparation
Stop the engine.
breather.
Push the pressure release button to
bleed air.
To measure the main pump pressure.
assembly main pump gauge port as
shown.
2507A7MS03A
505C.
(2) Measurement
Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
In the swing function, place bucket
against an immovable object and
measure the relief pressure.
In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Remarks
Boom, Arm, Bucket 350 (380)10 -
R220LC-9S Travel 35010 -
Swing 26510 -
( ) : Power boost
7-21

Section 7 Maintenance Standard

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SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test -------------------------------------------------------------------------- 7-1

speed, turn the upperstructure 180

travel, turn the upperstructure 180and

The measured drift should be within the following specifications.

The average measured pressure should meet the following specifications:

PILOT PRIMARY PRESSURE (CLUSTER TYPE 2)

R220LC-9S M mode 40 +20 -

Select the following switch positions.

Brake disengaged 40 Over 9

MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 2)

R220LC-9S High idle 405 -

against an immovable object and

Boom, Arm, Bucket 350 (380)10 40010

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